ASSIGNMENT APCE

1. With a neat sketch write a short note on cyclone separator.

Ans.

Principle:
A cyclone separator is a device that utilises the diffused centrifugal force generated by a spinning gas stream to
separate the suspended particles from the flue gas streams. The centrifugal action throws the heavy coarser
particles to the cyclone wall where they can slide down into a collector. The separator operates with two
vortexes as shown in Fig

In fact, the centrifugal force is locally opposed by aerodynamic drag in the radial direction; hence, the particles
get carried towards the bottom of the cyclone. However, the finer particles exit from the top along with the flue
gas.
The centrifugal force on particles in a spinning gas stream is much greater than gravity therefore cyclones are
effective in the removal of much smaller particles than gravitational setting chambers and requires much less
space to handle the same gas volume.

In operation/working, The particulate—laden gas stream is forced (tangentially) to spin in a cyclonic or

rotating motion to form the vortex. The vortex so formed develops a centrifugal force, which acts to throw the
particles radially towards the wall. The gas spirals downward to the bottom of the cone, (forming an outer
vortex) and at the bottom, the gas flow reverses to form an inner vortex which leaves through the outlet pipe at
the top. It is in this outer vortex that removal of particulates occurs. This vortex acts as the settling chamber or
zone.

APPLICATIONS :
1) Cyclones are widely used in cement manufacturers, feed and grain processing and wood working industries
for the control of gas borne particulates.
2) They are used in rock crushing, ore handling, sand conditioning in industries to separate dust in
disintegration operation.
3) Also used as catalyst dusts in the petroleum industry and in the reduction fly ash emissions.

The efficiency of the cyclone separator depends on the:

1. Size and density of the particles;
2. Flue gas inlet velocity and its viscosity (which is function of the temperature); and
3. Cyclone geometry viz. the cyclone diameter, length of cone, length of shell, flue gas inlet and outlet
diameters.
The high efficiency cyclone is one with a diameter of 22.5 cm or less. At peak performance, a high efficiency
single cyclone would only collect particles of about 2 μm diameter at efficiency of about 50 to 60% by weight.

Low: 50–80% collected by weight Medium: 80–95% collected by weight High: 95–99% collected by weight

Two Types of Cyclone Seperator;

1. Large diameter cyclones known as Reverse flow Cyclone Separator.

2. Small diameter Multi-Cyclones
 2. Enlist the types of filters. Explain the four types of collection mechanism of contaminants in
filters.

Ans.

Based on application requirements in industrial, commercial and medical sectors , there are several types of
common Filters available;

1. Fabric Filter
2. Ionic Air Filter
3. HEPA, (high efficiency particulate absorbing)
4. Carbon Air Filter
5. UV light air Filters

Types of Fabric Filter/Bagfilters based on the cleaning method as:

1. Shaker type bag Filter
2. Reverse-air type Bag Filter
3. Pulse-jet type Bag Filter

Collection mechanism of contaminants in filters;

Following mechanisms responsible for the particle removal from the gas stream in Filtration are:
1. Inertial impaction;
2. Brownian diffusion;
3. Electrostatic attraction;
4. Sieving; and
5. Direct interception
1. Inertial Impaction: Impaction is an inertial mechanism that is most effective on particles larger than about
1μm. Inertial impaction occurs when the particles get deposited on the (curved) surface due to high inertia as
they depart from the stream flow line.It is effective in fabric filters because there are many sharp changes in
flow direction as the gas stream moves around the various particles and fibres.

3. Brownian diffusion: A Brownian diffusion mechanism refers to the zig-zag motion of the particles
caused due to their collision with the gas molecules. The zig-zag random Brownian motion causes the
particles to impinge and adhere to the surface of the fibre. Diffusion mechanisms are moderately
effective for collecting submicron size particles-in the range of 0.001 to 0.05 μm. Such small size
particles usually do not follow the gas stream lines.
 4. Electrostatic attraction: Particles can be attracted to the dust layer and fabric due to the moderate
electrical charges that accumulate on the fabrics, the dust layer, and the particles. Both positive and
negative charges can be generated, depending on the chemical make-up of the materials. Particles are
attracted to the dust layer particles or fabric fibre when there is a difference in charge polarity or when
the particle has no electrical charge. The generation of electrostatic charges in filter fabrics may be due
to friction between gas and fabric as well as that between particles and fabric at high gas velocities of
1.0 to 2.0 m/s. Stronger electric charge results in greater particle removal.

4. Sieving: The particles are removed physically simply due to their size being larger than the pore size of the
filter fabric. Usually, sieving (of particulate matter) occur after the dust cake is fully established.

5. Direct Interception: The particles having low inertia almost follow the gas streamlines around the
obstruction. The particles while clearing the obstacles come in contact with the fibre and are intercepted
 3. Write a short note on Venturi Scrubber.

The Removal Mechanisms: The mechanisms affecting the collection of particulates in the venturi scrubber are
inertial impaction, diffusion, electrostatic phenomenon, condensation and agglomeration. The predominant of
all these is the inertial impaction.

Working: It is a high energy wet scrubber with good efficiency. A venturi scrubber has a converging-diverging
flow channel A venturi scrubber accelerates the moving waste gas stream to atomize the scrubbing liquid into
droplets and to improve gas-liquid contact. In a venture scrubber, a “throat” section is built into the duct that
forces the gas stream to accelerate as the duct narrows and then expands. In this , the particulates laden stream is
directed through a Venturi tube at throat velocity of 60-100 m/s. As the gas enters the venture throat, both gas
velocity and turbulence increase. Depending on the scrubber design, the scrubbing liquid is sprayed into the gas
stream before the gas encounters the venturi throat, or in the throat, or upwards against the gas flow in the
throat. The scrubbing liquid is then atomized into small droplets by the turbulence in the throat and droplet-
particle interaction is increased. The gas-liquid mixture then decelerates as it moves through the diverging
section, causing additional particle-droplet impacts and agglomeration (grow into a mass) of the droplets. The
liquid droplets are then separated from the gas stream in an entrainment section, usually consisting of a cyclonic
separator and mist eliminator

The Removal Efficiency:

Venturi scrubbers offer high performance efficiency for the collection of fine particles, usually less than 2 to 3
μm in diameter

Venturi scrubbers are more expensive than spray towers, cyclone separators or packed bed and plate column
towers but collection efficiencies for the PM are higher. Capital and operation and maintenance costs are
moderately higher than the costs of simple spray towers.

These are used for removing mist, dust from gases, various metallurgical furnaces and sulphuric acid
concentrations. employ liquid solutions—typically water—to collect and remove water-soluble gas and
particulate pollutants from industrial emissions.
4. Write a short note on Electrostatic Precipitator.

Ans.

The electrostatic precipitator is one of the most widely used devices for controlling particulate emissions from
industrial installations ranging from house hold appliances to power plants, cement and proper mills and oil
refineries. They are usually used to handle large volumes of gases e.g., at Thermal Power Plants (to handle fly
ash), Cement kilns and Paper mills, etc. In most cases, the particulates to be collected are by-products of
combustion i.e., they are dust fibres or small particles. In some cases acid mists from process industries can also
be controlled.

Working Principle : An ESP is an apparatus or equipment, which utilises an electric field to separate the
suspended particles from the dust laden flue gas. It is a physical process by which particles suspended in gas
stream are charged electrically and under the influence of the electrical field, separated from the gas stream.
Working/Operation :

The electrostatic precipitation consists of a positively charged (grounded) collecting surface and a high voltage
discharge electrode wire typically suspended from an insulator and held in position by weight at the bottom

Electrostatic precipitation is a physical process which involves four steps:

1. Charging of particles flowing between electrodes

2. Migration and collection of the particles on oppositely charged plates/surfaces
3. Dislodging the particles off the surface/plates into hoppers, and
4. Removal of the material from the hoppers.

Working/operation : The particle laden gas close to the negative electrode is ionised, upon passing through
the corona. As the negative ions and electrons migrate toward the collector electrode they, in turn, charge the
passing particulates. The particulates, under the effect of electrostatic field, are drawn towards the collector
plate where they are deposited. The collected material is removed, usually by hitting or vibrating the
collector, a process which is called rapping. The dislodged particles fall down below the electrical treatment
zone and are collected for disposal. If a mist is being collected, then the material runs down the collectors and
is removed at the bottom.
There are two types of ESPs:
1. Tube type or pipe and wire precipitator and
2. Plate type precipitator.
Application Based Classification of ESPs
Three different types of ESP’s are used for different applications such as:
1. Negatively charged dry precipitators:
2. Negatively charged wet-wall precipitators:
3. Positively charged two-stage precipitators:
APPLICATIONS
1) Cement factories : Cleaning of floogas from cement kilns, recovery of cement dust from kilns.
2) Pulp and paper : Soda-Fume recovery in kraft pulp mills.
3) Steel plants : Cleaning blast furnace gas, removing tars from coke over gases, cleaning open hearth and
electric furnace gases.
4) Chemical Industries – collection of Sox. Phosphoric Acid mist, cleaning various types of gases i.e.,
hydrogen, CO2, SO2, Removing dost from elemental phosphorus in the vapor state.
5) Petroleum industry:- Recovery of catalyst.
6) Carbon black industry :- Agglomeration and collection of carbon black.
7) Thermal Power plants:- collecting Fly ash from coal fired boilers.
 5. Explain in detail about the equipment for gaseous pollutant control.

Ans.

The gaseous pollutant control equipments works on the following methods for controlling gaseous
pollutants;
1. Absorption;
2. Adsorption;
3. Condensation;
4. Incineration;
5.Catalytic conversion;
6. Chemical reaction;
7. Selective diffusion through a membrane; and
8. Bio filtration.

These methods either involve recovery or destruction of gaseous pollutants.

The gaseous pollutant equipments are,

A) The Absorbing Equipments

1. Packed towers
2. Plate towers 1. Bubble-cap towers 2. The sieve plate tower
2. Perforated-plate towers
3. Spray towers
4. Venturi scrubbers
5. Flue Gas Desulfurization by Absorption Cleaning
6. Wet Lime/Limestone FGD
7. Spray Drying Absorption
8. Other Applications in Gas Cleaning
9. Removal of NOx by Absorption
10. Absorption of HF/SiF4

B) The Adsorption equipments

1.Fixed Bed Adsorption Tower

2. Moving Bed Adsorption Tower
3. Fluidized bed system
4. VOC cleaning by Adsorption
4. Application for cleaning of other gases by Adsorption
C) Catalytic conversion

1. Catalytic Oxidizers for VOCs

2. SO2 Oxidation
3. Catalytic Reactor -SCR of NOx
4.Photo catalytic oxidation of VOCs
5.Applications in Gas Cleaning
D) Incineration -Thermal Incineration, direct combustion, Catalytic combustion

E) Condensation – Direct & Indirect contact Condenser(Water based), Refrigeration Condensers and
Cryogenic System
F) Biological Treatment of VOCs-BIofilteration

1. Packed Tower : the tower (vertical shell) is filled with a pack material that is supported on the plate. The
packing material ranges from a specially designed ceramic packing to crushed rock. In general, the packing
should have large surface area per unit volume and low pressure drop of gas through it.
The liquid is uniformly distributed over the packing by using either spray systems, overflow weirs or a
perforated distribution plate. The liquid is scattered to form the thin film on the surface of packing and flow
downward through the voids between the packing.

2.Plate Towers:
Plate or tray towers are essentially vertical cylinders with horizontal plates so arranged as to permit the liquid
and gas contact in stepwise fashion (i.e., stage operation) on (plates or trays) them. The liquid enters at the top
and cascades from each stage to another and eventually is collected and withdrawn from the tower bottom. i.e.,
the liquid flows across each plate and through a down spout to the plate below. The gas passes through openings
of one sort or another in the plate at each stage forming bubbles. Absorption takes place during bubble
formation and their upward movement through the liquid.

In bubble-cap towers, the gas enters each plate through the gas risers and is forced into the bubble cap with
opening to come out as bubble and move into the surrounding liquid on the plate. Plate towers are effective for
absorption

Spray Towers:
Spray tower or spray chamber consists of empty cylindrical vessel made of steel or plastic and nozzles that
spray liquid into the vessel. The inlet gas stream usually enters the bottom of the tower and moves upward,
while liquid is sprayed downward from one or more levels. This flow of inlet gas and liquid in opposite
direction is called the counter current flow. Theoretically, the smaller the droplets formed, the higher the
collection efficiency achieved for both gaseous and particulate pollutants

Venturi Scrubber :: It is a high energy wet scrubber with good efficiency. In this , the particulates laden stream
is directed thorugh a Venturi tube at throat velocity of 60-100 m/s. Water sprays are introduced just ahead of the
Venturi throat. Inertial impact is the primary collection mechanism, consequently the faster the gas passes
thorugh the Venturi, the higher the efficiency. They are used routinely for small gas rates that contain
predominantly small particles. These are used for removing mist, dust from gases, various metallurgical
furnaces and sulphuric acid concentrations.

Flue Gas Desulphurisation [FGD] – Oxides of Sulphur (SOx) adversely affects the environment.
Desulphurisation helps in reducing the harmful effects of SOx through dry, semi-dry and wet systems. Major
Industries Power plant, Glass furnaces, Oil Fired boiler and Turbines

Adsorption tower : There are two main types of adsorption systems; fixed bed or continuous.

Fixed bed absorber. 2. Moving bed absorber.

Fixed bed absorber - It consists of an absorbent bed (granulated activated carbon) through which the polluted
gas is passed from the top, which then travels downwards and leaves through the bottom. The single bed
absorber may be operated to the breakthrough point and then must be regenerated.

Moving bed absorber- • It consists of a cylindrical bed which slowly rotates about its axis. • The absorber bed
moves from polluted fluid to the regeneration fluid to the drying & cooling fluid.

Bio filtration:
The biological systems are termed either biological oxidation or bio filter systems. Regardless of the term, the
fundamental process involved is the collection of contaminants on the surface of a media that contains viable
microorganisms. The contaminant is metabolised by the organism and carbon dioxide and water vapour are re-
emitted. Accordingly, bio filtration can be classified as a special type of adsorption system using irreversible
processes to control the gaseous contaminant. The fundamental principle is that organic gaseous pollutants are
absorbed into liquid phase, which are utilised by microorganisms as source of carbon (i.e., food) or energy
source. In the process, organics are destroyed and converted into inert end products, CO2 and H2O. The basic
process involves contacting the contaminated air stream with a circulating liquid or a wetted bed that contains a
healthy population of biomass. Fixed bed or the stationary media configuration of the bio filtration is most
commonly adopted in which the water and biomass are maintained on the bed.

Condensation:
Condensation systems are used exclusively for the recovery of organic compounds (VOCs) present at moderate-
to-high concentration in industrial process emissions (effluent gas stream). Condensation is particularly
effective in the recovery of organic compounds which have relatively low vapour pressures at room temperature
e.g., compounds that are nearly converted to liquids at room temperature. Higher the vapour pressure (of
compounds) more volatile the compound is. The most common type of condensers are those using cooling
water in direct or indirect contact vessels. Direct contact condenser usually atomises a cooled, re circulated, low
vapour pressure liquid such as water into the gas. The recycled liquid is often cooled in an external exchanger,
shell and tube type condensers and provide indirect contact.
Refrigeration and Cryogenic systems are used primarily for the high efficiency recovery of high value
contaminants.

Incineration:
If the gas stream contains sufficient combustible materials then incineration may be the simplest route in air
pollution control. It can be broadly applied for the control of all VOCs. It is often called thermal oxidation or
after burning. It involves destruction of VOCs/organic compounds through complete combustion. The organic
compounds/VOCs are destroyed by oxidation to CO2 and H2O. The products of combustion of organic
materials are normally odourless, colourless and harmless giving off CO2 and H2O vapour. It is an excellent
process to destroy odorous and toxic substance (such as pesticides) because it permanently destroys organic
compounds. But it is not a good method for treating metal containing compounds. High molecular weight
hydrocarbons could cause smoke problems

Thermal incineration is the most efficient as well as the most flexible technique for destroying the diluted
combustible gases. The thermal incinerator or oxidiser is simply an open cylinder with a burner at one end to
create a flame

Catalytic oxidisers can reduce the temperature required for destruction of VOCs/organic compounds as the
combustion takes place [on a catalyst] usually at temperature several degrees below those required for thermal
incineration. This can save considerable fuel and operating expenses compared with thermal oxidisers.

The catalytic combustion is recommended for gases that are free of particulate matter and certainly free of
metallic substances which could poison the catalyst. The catalyst bed needs to be cleaned periodically by
scrubbing with water or acid and by heating to high temperatures.
 6. With a neat sketch explain bag filter.

The Bag filter system typically consists of a tubular bag or an envelope called filter bags, numerous vertical
bags 120-400mm diameter and 2-10m long are housed together which are suspended or mounted in such a
manner that the collected particles fall in a hopper which is attached at the bottom for the collection of dust
when dislodged from the fabric during cleaning cycle with open ends attached to a manifold, and a hopper.
Several of these bags are grouped together and put into a compartment. As the name indicates is in the form of a
Fabric bag arrangement or cloth envelops.

Particle Removal Mechanisms

In principle, the dust laden gas passes through a fabric in which the particles are trapped due to multiple modes
of particle capture that occur within the dust cake and fabric. The multiple mechanisms responsible for the
particle removal from the gas stream are:
1. Inertial impaction;
2. Brownian diffusion;
3. Electrostatic attraction;
4. Sieving; and
5. Direct interception

Working : The gas entering through the inlet pipes strikes a baffle plate, which causes the larger particles to fall
into a hopper due to gravity. The carrier gas then flows upwards into tubes and then outward through the Fabric
porous filter media which filters off the particles leaving the surface of the bags, and allows the clean gas to
pass through . This requires a periodical cleaning by rapping, shaking or vibration or by reverse air flow.
In this process, a layer of dust (cake) forms on the filter surface, resulting in increased pressure drop across the
filter. The filter cake i.e., the deposited dust layer must be removed when the pressure drop reaches the
maximum limit, or at a preset filtration time, in order to maintain the filter operation without any problems. The
bag filters are normally operated at steady gas flow, which is maintained by a downstream fan, to overcome the
increased pressure drop across the filter. The filter cake is removed periodically by applying high pressure
reverse jet pulses or by any other suitable rapping mechanism depending on the type of bag filter. The reverse
jet-pulse cleaning mechanism involves injecting high pressure back pulse air into the filter bags for a very short
time causing sudden expansion of the filter medium and dislodgement of a particle cake from the filter surface.

APPLICATIONS
Fabric filters are extensively used in the follows industries and operations.
1) Metallurgical industry
2) Foundries
3) Cement lime plants
4) Chalk and lime plants
5) Brick works
6) Ceramic industry
7) Floor Mills etc.

Types of Bagfilters
As shown in Fig. 8.12, the Bag houses are classified based on the cleaning method as:
1. Shaker type
2. Reverse-air type
3. Pulse-jet type
Signification of A/C ratio:
As the air-to-cloth ratio increases, the localised gas velocities through the dust cake and fabric increase.The net
result of seepage and pore collapse, caused due to high air-to-cloth ratios, is increased particulate matter
emissions decreasing the efficiency.

Parameters that affect the performance of bag filters are:

1.Flue gas parameters

(i) Temperature
(ii) Due point
(iii) Moisture content

2.Particles
i)Particle size distribution
(ii) Chemical composition of dust
(i) The operating pressure of the system
(ii) Air-to-Cloth ratio.

3.The system

(i) The operating pressure of the system

(ii) Air-to-Cloth ratio.

7. Give the advantages and disadvantages of following air pollution control equipment:

1. Electrostatic Precipitator
2. Venturi Scrubber
3. Bag Filter
4. Cyclone Separator
5. Gravity Settler

1. ESP

Advantage:
 Maintenance is nominal, useless corrosive and adhesive materials are present in flue
gases.
 They contain few moving parts.
 They can be operated at high temperature up to 300oC-450o C.
Disadvantage:
 Higher initial cost.
 Sensitive to variable dust loading and flow rates.
 They use high voltage, and hence may pose risk to personal safety of the staff.
 Collection efficiency reduces with time.

2. VEnturi Scrubber
Advantages : Increasing the pressure drop in a Venturi scrubber increases the efficiency, high collection
efficiencies of PM ranging from 70% to 99% for particles greater than 1μm in diameter and greater than 50%
for submicron particles
Disadvantages: system’s energy demand also increases leading to greater operational costs, The disadvantage of
this device is the high pressure drop and hence high operating power costs., more expensive than, Capital and
operation and maintenance costs are moderately higher than the costs of simple spray towers.

Advantages of Venturi Scrubbers

• Capable of handling flammable and explosive dusts
• Can handle mists in process exhausts
• Relatively low maintenance
• Simple in design and easy to install
• Collection efficiency can be varied
• Provides cooling for hot gases
• Neutralizes corrosive gases and dusts
Disadvantages of Scrubbers
• Effluent liquid can create water pollution problems
• Waste product collected wet
• High potential for corrosion problems
• Requires protection against freezing
• Final exhaust gas requires reheating to avoid visible plume
• Collected PM may be contaminated, and not recyclable
• Disposal of waste sludge may be very expensive

3. Bag Filter:

Advantage: Fabric filters can give high efficiency, and can even remove very small particles in
dry state.
Disadvantage: High temperature gasses need to be cooled. The flue gasses must be dry to avoid
condensation and clogging. The fabric is liable to chemical attacks.
 4. Cyclone Separator

advantages such as:

1. Simple structure;
2. Low cost;
3. Less space requirement;
4. Capability to withstand high pressure and high temperature conditions;
5. No moving parts, hence low maintenance cost;
6. Low pressure drops, hence less energy consumption; and
7. Can be subjected to higher inlet dust concentrations than fine particle control devices.

Disadvantages : The major limitation of cyclones is the low removal efficiency for fine particles.

5. Gravity Settler

Advantages :

1.They offer low pressure drop and require simple maintenance,

2. Low capital cost;
3. Very low energy cost;
4. No moving parts, therefore, few maintenance requirements and low operating costs;
5.Excellent reliability;
6.Device not subject to abrasion due to low gas velocity;
7.Provide incidental cooling of gas stream;
8. Temperature and pressure limitations are only dependent on the materials of construction; and
9.Dry collection and disposal.

Disadvantages :

1.The very low terminal settling velocities of most particles limit the usefulness of such devices.
2. Relatively low PM collection efficiencies, particularly for PM less than 50 micrometer in size;
3. Unable to handle sticky or tacky materials;
4. Large physical size; and
5.. Trays in multiple-tray settling chamber may warp during high-temperature operations.
6. The most common failure mode of settling chambers is plugging of the chamber with collected dust. In
expansion settling chambers the plugging can result from hopper bridging or hopper discharge seal failure.
7.Multiple-tray settling chambers may experience plugging of the individual gas passages.

Gravity settlers are used only to remove large particles above approximately 50 μm. their particle removing
efficiencies are quite low, particularly for particles less than 50 μm. these devices are usually used as pre
cleaners prior to passing the gas stream through high efficiency collection devices.
8. Draw a neat sketch of absorption Tower. Give the advantages and disadvantages of gravity settler.

Figure???

Gravity Settler
Advantages :

1.They offer low pressure drop and require simple maintenance,

2. Low capital cost;
3. Very low energy cost;
4. No moving parts, therefore, few maintenance requirements and low operating costs;
5.Excellent reliability;
6.Device not subject to abrasion due to low gas velocity;
7.Provide incidental cooling of gas stream;
8. Temperature and pressure limitations are only dependent on the materials of construction; and
9.Dry collection and disposal.

Disadvantages :

1.The very low terminal settling velocities of most particles limit the usefulness of such devices.
2. Relatively low PM collection efficiencies, particularly for PM less than 50 micrometer in size;
3. Unable to handle sticky or tacky materials;
4. Large physical size; and
5.. Trays in multiple-tray settling chamber may warp during high-temperature operations.
6. The most common failure mode of settling chambers is plugging of the chamber with collected dust. In
expansion settling chambers the plugging can result from hopper bridging or hopper discharge seal failure.
7.Multiple-tray settling chambers may experience plugging of the individual gas passages.

Gravity settlers are used only to remove large particles above approximately 50 μm. their particle removing
efficiencies are quite low, particularly for particles less than 50 μm. these devices are usually used as pre
cleaners prior to passing the gas stream through high efficiency collection devices.

9. Write a short note on fixed bed and moving bed adsorption tower.

Fixed bed absorber. 2. Moving bed absorber.

Fixed bed absorber - It consists of an absorbent bed (granulated activated carbon) through which the polluted
gas is passed from the top, which then travels downwards and leaves through the bottom. The single bed
absorber may be operated to the breakthrough point and then must be regenerated.

Moving bed absorber- • It consists of a cylindrical bed which slowly rotates about its axis. • The absorber bed
moves from polluted fluid to the regeneration fluid to the drying & cooling fluid.

There are two main types of adsorption systems; fixed bed or continuous.

Fixed Bed Adsorption tower : Fixed bed or packed bed systems are quite simple devices. A thoughtful design
will look to maximize surface area to promote full and even use of the adsorbent. An example flow diagram is
shown below. In this system, the contaminated gas enters the fixed bed vessel at the side. The adsorbent
material (consider this to be activated carbon) is contained in a packed bed arrangement that allows for as much
exposed surface area as possible. The polluted air enters the activated carbon packing and works towards the
center, where there is an exhaust distributor. The exhausted air exits the fixed bed adsorber clean of pollutants
or contaminates. 
 
Once the adsorbent is fully saturated with adsorbate (leading to breakthrough), the system requires change-out
of the spent materials with new materials. This is typically accomplished through a sub-contractor that
specializes in adsorbent materials and service. The spent adsorbent will be thermally cleaned by the sub-
contractor at off-site facilities specially designed for this purpose. 

Moving Bed Adsorption Tower : Continuous systems are more complex and provide continuous operations
without having to conduct manual change-out of adsorbents. These systems provide in-situ desorption of the
adsorbates from the adsorbent. This can be accomplished with superheated or saturated steam. In these systems,
the adsorbate can be condensed, collected, and re-used in the process. The process is exactly as described
above, but there are two adsorbers used in the system. The gases are being adsorbed in one unit as the other unit
is being desorbed with steam. The exhaust from the desorbed bed can be condensed for solvent reuse or other
beneficial purpose. 
A second type of continuous adsorption device is a Zeolite Concentrator, or Rotary Concentrator. In these
systems, a hydrophobic zeolite is designed in a monolithic rotor in which the contaminated air stream flows
over a large percentage of the rotor. An integrated thermal oxidizer is used to provide desorption of the solvents
from the zeolite and final destruction. Rotary Concentrators or Zeolite Adsorbers have wide acceptance in
industrial air pollution control applications that have very high volumes and low concentrations.

Adsorption is a mass transfer process in which a porous solid comes in contact with a liquid or gaseous stream
to selectively remove pollutants or contaminates by depositing (adsorbing) them onto the solid. The
contaminates being removed are referred to as the adsorbate, and the solid doing the adsorbing is called the
adsorbent. 
Adsorption devices are commonly used in many industrial applications.
The adsorption process can be both a physical and chemical process. The most common adsorbents used in
industry are activated carbon, silica gel, activated alumina (alumina oxide), and zeolite. The most efficient
method for promoting adsorption is in a packed bed through which the polluted air stream being treated passes.
As the stream passes through the bed, adsorption of the contaminates takes place, and the purified air exits the
packed bed. 

Adsorption systems are configured either as stationary bed units or as moving bed units. In stationary bed
adsorbers, the polluted airstream enters from the top, passes through a layer, or bed, of activated carbon, and
exits at the bottom. In moving bed adsorbers, the activated carbon moves slowly down through channels by
gravity as the air to be cleaned passes through in a cross-flow current.
10. What is absorption tower? Explain in detail with neat diagram.
Ans

Absorption tower is equipment used to for the removal of gaseous pollutants, which involves absorption of
impurities from the rising gas in Column.

Working principle of Absorption Tower :

Absorption Tower works on ABSORPTION process. Absorption is scrubbing or diffusion process in which
involves the transfer of the pollutant from the gas phase to the liquid phase across the interface (between
absorber and absorbent). There can be physical and chemical absorption. Physical absorption makes use of the
remarkable solubility of a gaseous pollutant in the solvent and involves only the dissolution process. Chemical
absorption involves the chemical reaction between the gas and the absorbing liquid. Water is the most
commonly used absorbent liquid.

Removal Mechanism:
In the physical and chemical absorption, the mechanism by which the species is removed from the gas consists
of the three steps that occur in series.

1. diffusion of the pollutant molecules from the gas (air) to the surface of absorbing liquid;

2. dissolution (of the gas molecules) into the liquid at the interface; and
3. diffusion of the dissolved species from the interface into the bulk of the liquid.

Operation/Working

The Absorption tower (vertical shell) is filled with a pack material that is supported on the plate. The packing
material ranges from a specially designed ceramic packing to crushed rock. In general, the packing should have
large surface area per unit volume and low pressure drop of gas through it. The liquid is uniformly distributed
over the packing by using either spray systems, overflow weirs or a perforated distribution plate. The liquid is
scattered to form the thin film on the surface of packing and flow downward through the voids between the
packing. Normally, the liquid and gas flow counter current to each other, the gas flowing upward and the liquid
flowing downward. The wetting surfaces of packing thus provide the contact sites for gas and liquid and
facilitates the absorption of impurities. The aerosolized fluid will carry the impurities towards the bottom of the
absorption tower and thorough the outlet. The clean air will flow upwards and out of the absorption towers
through the clean air outlets.
Typical Packed bed Absorption Tower-Definition Sketch

The commonly adopted absorbing Towers are such as

1. Packed towers
2. Plate towers 1. Bubble-cap towers
2. Perforated-plate towers
3. Spray towers
4. Venturi scrubbers

Plate or tray towers are essentially vertical cylinders with horizontal plates so arranged as to permit the liquid
and gas contact in stepwise fashion (i.e., stage operation) on (plates or trays) them. The liquid enters at the top
and cascades from each stage to another and eventually is collected and withdrawn from the tower bottom. i.e.,
the liquid flows across each plate and through a down spout to the plate below.
In bubble-cap towers, the gas enters each plate through the gas risers and is forced into the bubble cap with
opening to come out as bubble and move into the surrounding liquid on the plate
The perforated or sieve plate towers consist of plates with holes (3 mm–20 mm) in them The gas rises through
the holes while liquid moves down wards in a counter current flow pattern i.e., the gas flows in a counter
current direction to the dropping liquid (through the holes) and forms the bubbles.

Spray tower or spray chamber consists of empty cylindrical vessel made of steel or plastic and nozzles that
spray liquid into the vessel. The inlet gas stream usually enters the bottom of the tower and moves upward,
while liquid is sprayed downward from one or more levels
Removal Efficiency : In general, absorbers can achieve removal efficiencies greater than 95%. One potential
problem with absorption is the generation of wastewater, which converts an air pollution problem to a water
pollution problem. For gas absorption, spray towers are not as effective as the packed towers or plate towers.
Plate towers are effective for absorption. Efficiency can be increased by the addition of plates and the tower
height

The requirements of efficient absorption Tower with low capital and operating cost are as under:
1. Large contact surface between gas and liquid: Large surface area of the absorber and a good contact between
the absorber and the absorbent maximise the process e.g., packed tower is a device which provides a large
surface area.
2. Enough contact time between two phases.
3. Highly turbulent mixing of gas and liquid.
4. Low pressure drop.
5. Steady operation and appropriate flexibility.
6. Simple device easy for maintenance.